Wednesday 31 October 2007

Nobody (A Halloween Story)

A slight detour from my usual subject matter today because The Goldfish has cajoled me into writing a 'spooky' story for JackP's Halloween Story Collection. So, if you are seated comfortably, we shall begin:


It came as no surprise to Alan that nobody met him at the school gate. For a short while after mummy went to live with the angels, daddy had come instead. But life had to go on they said and he was a big boy now. Daddy had to go back to work and Grandpa John lived only just around the corner. Too far for his old legs, but near enough for a big boy like Alan to walk there on his own.

So nobody took Alan's hand at the gates and enquired about his day in school. Alan forgot to count the cedar trees at the side of the road and recalled the day's events while walking to the place where it was safe to cross. Nobody watched over him as he looked right and left, and right again, before going straight across the road.

Just a little further along, and around the corner, and there was Grandpa John looking our from the window of his house. The door was open before Alan had opened the gate and run up the garden path, and as Grandpa John welcomed him in Alan turned and waved good bye.

"See you tomorrow" he shouted.

Grandpa John looked out to the empty street. "Who are you calling to?" he asked.

"Oh, nobody" Alan replied.

Friday 12 October 2007

Starter Motor Bush Puller

I remember my friend Tex commenting that my father "wasn't a bodger". An odd thing to say and while it wasn't a compliment, it wasn't an insult either. Merely an observation.

You see my father, in his capacity as a bench joiner had amassed an extensive collection of tools. Some of them sat in cupboards and drawers for years on end between uses however when they were used, having the right tool for the job made a world of difference. Not having the right tool, on the very rare occasions that it happened, was an intense source of frustration to him.

Tex on the other hand, though also a joiner, made his living going out and about fixing things. His need to be mobile meant that he could only carry a relatively small number of tools and he often found himself having to use things for purposes other than the one for which they were strictly intended, and having to implement less than perfect solutions in order to just get the job done - or "bodging" as he called it.

The reason this comment, which was made some 15 years ago, came to mind is that I have just installed a new starter motor in my Bay, and while the removal of the various nuts and bolts went a lot easier than I expected, the bush seemed determined to stay firmly in the clutch housing.

Not wanting to damage anything, I abandoned the job overnight in order to post on VZi asking how to remove it. Moby5153 came to my assistance as he has done before and pointed out that there's a special tool available for the job, or that I could tap into it with an M12 tap.

I didn't have an M12 tap but as the bush is copper, a high tensile M12 bolt did the job quite nicely, tapping into it and then pushing the bush out as the bolt made contact with the clutch housing. The new starter motor is now in place and all seems well.

Now, while this might be the first starter motor bush I've ever had to deal with, I dare say it won't be my last so I'm looking at that special tool in the VW Heritage catalogue and thinking that perhaps I should add the 40 quid item to my shopping list. Thus I find myself with miniature versions of my father and Tex sitting on my shoulders like angel and demon (although I'm not sure which is which), with my father reassuring me that it'll be 40 quid well spent, and Tex shaking his head in despair.

Monday 8 October 2007

Red 9 Design EZRider - Shocks

It's taken me a couple of days longer to post this than I expected. Damned CFS. However:

In my previous post I explained my reasons for purchasing Red 9 Design's EZRider kit and my thoughts regarding the safety concerns expressed by some. In this post I'll describe what I've installed so far, namely the shocks/dampers (which I will refer to as "shocks" from here on).

The EZ Rider kit consists of 2 elements:

The first is a pair of metal bars that replace the torsion bars. These are metal rods with the necessary dimples machined into them and swivelling ends that will allow the trailing arms to pivot freely.

The second element is a pair of Spax coil over shocks.

In order to lower a van from stock height you need the rods in place or the torsion bars will continue to determine it's height, however as my intention was to raise a van that had been lowered too far it occurred to me that the shocks alone might do it. Given that they were going to be easier to fit than the rods I decided to try them on their own first and see what happened.

The only problem I encountered in fitting the shocks was that the bushes in the lower end of the dampers wouldn't go onto the spindles. I didn't measure it but we're talking about maybe a thousandth of an inch too tight, two at most. Given that this was an issue with the shocks I decided to phone Spax as opposed to Red 9 Design and they suggested, given that it was such a small amount, that I check there was no rubber fouling things and if there wasn't then maybe making the hole in the bushes a little bigger. There was no problem with rubber and I found that a 12mm drill went snugly thought the bushes. Running the drill backwards and forwards a few time removed a tiny amount of metal after which they went snugly onto the spindles. Everything was easy after that and it was unnecessary to compress the springs.

Before moving on to the results I'd just like to mention an interesting aspect of the phone call to Spax: while talking to them I found out that these shocks are made especially for Red 9, to their specification. Given that I was wanting to raise my van and was speculating that the shocks alone may be enough to do, I had wondered whether the purchase of a pair of coil over shocks alone might be enough. Indeed I asked VWHeritage about using their GAZ coil over shocks for this purpose however they doubted that their springs would be powerful enough to actually raise the van. I didn't fancy gambling 200 quid on something that might not work. Better I thought to pay 320 for something that WILL work even if it turns out that I don't need the entire kit.

So how about the results?

Here she is before:



and after the shocks were fitted:



As you can see she's now about 2.5" higher at the front than she was before; which is just what I wanted because I now have about 4.5" inches of ground clearance under the low points on the beam.

She still has low profile tyres on the front and although I'll leave them in place for now I'll change them to something bigger when they need changing. That'll take her up about another half an inch however at that point I might use the adjustments on the coils to bring her down half an inch, maybe a full inch.

She is actually about an inch higher at the front than she is at the back now but I'd like to take her up an inch at the back. At the moment you have to deflate the tyres to get them out from under the rear arches. Going up an inch will remove that hassle.

As for the ride, I can't really say at the moment. To be honest it doesn't feel much different but:

1. I haven't driven her much since doing it.

2. I haven't fitted the torsion bar replacements.

3. I haven't touched the adjustment screws on the shocks.

I'll report back on the ride in a few weeks time. By then I'll have done a few more journeys and will have Dee's opinion too. Up until now she's been complaining that if I couldn't improve it she'd have to invest in some sports bras so we'll have to see how the ol' bounceometers rate it now. I may also have twiddled with the adjusters (on the shocks, not on the bounceometers).

What I do about the torsion bars is another issue. As I said before, if I were lowering the van I'd have to swap them but given what I'm doing I can't really see much point. As I understand it, it can't improve my ride as her height is already being governed by the springs on the shocks i.e. the torsion bars ain't doin' nuffin' guv. The rubber seals on the ball joints are fubar (torn up, I've been told, as a consequence of her being lowered to much) so maybe I'll swap the bars when I deal with those rubbers. Maybe not. I haven't decided yet. At the moment I'm just chuffed that I don't have to worry about scraping the beam on every little bump in the road.

Friday 5 October 2007

Raisin' Up The Van

My van is too low. The previous owner lowered it as much as he could and even put low profile tyres on the front. I guess there must be no bumps in the road where he lives because I managed to scrape the low points of the front beam on the ground within my first week of ownership, and not on an obviously bumpy road either.

Raising her up a bit should have been simple given that there are adjusters on the beam however when I tried to move them, they wouldn't budge. I posted about it on earlybay.com and took her to a local-ish VW garage. The conclusion is that the installation of the adjusters was probably botched such that the internal collar has been locked in place by excessive weld penetration. The garage said they could fix it by removing them and fitting new ones at a cost of 250 quid.

At about this time, somebody posted on earlybay.com asking if anybody had any experience of the EZRider kit from Red 9 Design, thereby bringing the product to my attention. This is essentially a system for lowering a bus or bug by effectively doing away with the torsion bars and installing coil over shocks. It occurred to me that if the torsion bars were made redundant then my stuck adjusters would no longer be an issue and although the kit was 320 quid, Red 9 reckon that their kit gives a much better ride than a standard lowering job.

The idea of making an improvement rather than just a fix appealed to me however opinions about the kit seem to vary. The aforementioned thread on earlybay.com quickly turned into a discussion about safety rather than ride quality. A number of posters, and some mechanics that I've asked about it, point out that the damper mountings were not designed for this purpose. On the other hand, Red 9 Design have been making these items for several years now and there don't seem to have ever been any problems. I checked with my insurance company (Adrian Flux) and they had no concerns or warnings about it and all of the doubters on the forums seemed to be simply that i.e. doubters. I could not find, and I checked several forums, a single instance of anybody having had a problem with the Red 9 kit.

The main concern regarding safety seemed to be what would happen if the mounting failed however Red 9 are also able to supply lowered bump stops at an additional 47.50 per pair. I figure that having them in place is a reasonable safety precaution and added them to my shopping list. As a matter of fact I received the kit a few days ago and I fitted some of the kit today. I'll describe what I did, and report on the effect it's had, in my next post.